Apparatus utilized to construct modular homes

ABSTRACT

A modular home connector includes a main portion, wherein the main portion is formed via a first side, a second side, and a third side, wherein the first side and the second side are opposite of one another and substantially parallel with one another, wherein one or more ends of the first side and second side include a first angle with respect to the third side and at a perimeter of the first side or second side, wherein the first and second side are met by the third side, wherein the top perimeter of a first main portion aligns with the bottom perimeter of a second main portion, and a connector portion, wherein the connector portion includes a corresponding second angle to adjoin against a top perimeter of each side of the main portion and configured to connect two or more main portions via the connector portion.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application Serial No. 63/234,448 filed Aug. 18, 2021, the disclosure of which is hereby incorporated in its entirety by reference herein.

TECHNICAL FIELD

The present disclosure relates to an apparatus utilized to construct modular homes or other types of homes, including those utilizing shipping containers.

BACKGROUND

The shipping container is a common medium of transportation in the international (and domestic) transportation of goods. The shipping container may be one of the most cost effective forms of national and overseas transportation. By design, the shipping containers are readily transportable and have a sound structural integrity that provides great insulation and sound proofing, as well as rigidity.

As a result of globalization, new and used shipping containers are readily available in most countries. There are times when a company or corporation has excess shipping containers because it is not cost effective to return empty containers to their origin. Consequently, there are unused shipping containers throughout the world.

SUMMARY

According to a first embodiment, a modular home connector includes a main portion, wherein the main portion is formed via a first side, a second side, and a third side, wherein the first side and the second side are opposite of one another and substantially parallel with one another, wherein one or more ends of the first side and second side include a first angle with respect to the third side and at a perimeter of the first side or second side, wherein the first and second side are met by the third side, wherein the top perimeter of a first main portion aligns with the bottom perimeter of a second main portion, a connector portion, wherein the connector portion includes a corresponding second angle to adjoin against a top perimeter of each side of the main portion and configured to connect two or more main portions via the connector portion, and a floor connector that includes a bottom portion connected to a middle portion, wherein the middle portion is adjoined via a right angle with the bottom portion, and a top portion is adjoined to the middle portion via a third angle, wherein a flat surface of the middle portion that is away from the bottom portion and aligns with the connector portion.

According to a second embodiment, a modular home connector includes a main portion, wherein the main portion is formed via a first side, a second side, and a third side, wherein the first side and the second side are opposite of one another and substantially parallel with one another, wherein one or more ends of the first side and second side include a first angle with respect to the third side and at a perimeter of the first side or second side, wherein the first and second side are met by the third side, wherein the top perimeter of a first main portion aligns with the bottom perimeter of a second main portion, and a connector portion, wherein the connector portion includes a corresponding second angle to adjoin against a top perimeter of each side of the main portion and configured to connect two or more main portions via the connector portion.

According to a third embodiment, a modular home connector includes a main portion, wherein the main portion includes a first side, a second side, and a third side, wherein the first side and the second side are opposite of one another and substantially paralleled with one another, wherein one or more ends of the first side and second side include a 45 degree angle with respect to the third side and at a perimeter of the first side or second side, wherein the first and second side are met by the third side, wherein the top perimeter of a first main portion aligns with the bottom perimeter of a second main portion, wherein the main portion is configured to connect with a corresponding connector portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an exploded view of a modular connector.

FIG. 1B is an exploded view of a modular connector utilizing a connector with a bolt connection.

FIG. 2A shows an embodiment of a top view of the multiple connectors lined up to form a single story frame.

FIG. 2B shows an embodiment of a two-story home utilizing the apparatus.

FIG. 2C is an example of a floor connector.

FIG. 3A is a side view of multiple main portions connected via a hinge.

FIG. 3B is another side view of a multiple main connectors connected via a hinge.

FIGS. 3C and 3D are examples of configurations of the hinges 101 in operation.

FIG. 4A is a perspective view of a portion of multiple connectors.

FIG. 4B is a perspective view of a portion of multiple connectors that are framed.

DETAILED DESCRIPTION

Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications.

To overcome the problems and disadvantages experienced with the heretofore new and standard practices in modular building construction, the modular building system of the present disclosure has been devised. One embodiment of the disclosure may include a method to construct a home for building construction that can maximize the completion of the module in the factory environment where labor and quality can be controlled, that can have all of the framing done, thereby minimizing the work required to be completed in the field to create a habitable building. In other embodiments, is exterior claddings, windows, doors, interior finishes, cabinetry, plumbing, electrical, mechanical, and roofing installed and completed in the factory. The building module can be transported to a building site utilizing the intermodal shipping network or by a plurality of different shipping and transportation methods.

According to one embodiment, upon arrival at the building site, the building module is placed on and secured to a foundation or other form of support, the shipping contain may include the constructed modular connectors that are preassembled for the frame of the home. The modular connectors may be removed from the shipping container revealing a frame home or a home suitable for use as a habitable building, both in it singular use as well as the creation of a larger habitable building via joining a plurality of the modules together at the building site. In each of these embodiments, the system may require minimal work in the field at the building site to create the habitable building.

These and other objects of this invention are accomplished by providing a fully finished building module. The term fully finished refers to but is not limited to the installation and substantial completion in the factory prior to transport to the building site of a substantially finished floor assembly, substantially finished wall assemblies, substantially finished exterior window and door assemblies, substantially finished roof assemblies, substantially finished interior and exterior building finishes, cabinetry, plumbing systems and fixtures, electrical systems and fixtures and mechanical systems and fixtures.

FIG. 1A is an exploded view of a modular connector. The modular connector may include a base 101 and a connector portion 103. The connector may be shaped that it aligns with the connector when abutted. For example, at one end of the base, a 45 degree angle may be utilized to form a trapezoid on one side of the base. The opposite side of the base may also include a trapezoid shape with a 45 degree angle. The dimensions of the connector may be sized to any dimension, however, it may be sized according to building code or home building standards based upon the area of construction. For example, a base portion may be 7 feet, 8 feet, 9 feet, or 10 feet in length depending on whether it is utilized for a base of home or a stud for the ceiling.

The material of the modular connector may be steel or any other type of metal connection, such as aluminum or alloy or any similar metal. In another embodiment, the material may be a plastic or polycarbonate material that may be utilized to make a customizable outdoor storage area, shed, greenhouse, or similar structure. A top perimeter and bottom perimeter (or edge) of the main portion main abut against a connector portion. In another scenario, the top perimeter of the main portion may abut to the bottom perimeter of another main portion (or vice version) to form a right angle due to the 45 degree angels at the top and bottom perimeters of the main portion. The main portion may consist of three or more sides, but at least two of the sides has a 45 degree angle at a top end (e.g., top perimeter) or bottom end (e.g. bottom perimeter) with respect to a rectangular side that connects the sides. The sides may form an open gap between a left and right side away from the bottom side. The opening 105 or channel 105 may be utilized and sized for a subfloor or other framing components, as well as insulation or other materials. The opening 105 may form a C-channel, U-channel, I-beam, or any other beam.

FIG. 1B is an exploded view of a modular connector utilizing a connector with a bolt connection. As shown, a modified connector may utilize a bolt 150 and nut to screw into the base 120 that includes holes. While a bolt and nut is utilized, any type of fastener may be utilized, such as a screw, nut, pin, retaining ring, rivet, stud, cable ties, anchors, etc. The bolt may be inserted in a hole that is at a top portion of the connector 110. A head of the bolt may align with a top surface of a top side the connector portion while a bottom side of the connector portion secures another end of the bolt via the nut. Thus, a top side and bottom side of the connector portion includes a hole aligned to allow the bolt to run through. In another embodiment, the nut may be secure via a hole at a bottom surface of a top side of the main portion of the connector. In an alternative embodiment, the base and connector may be a single piece rather than separate pieces.

FIG. 2A shows an embodiment of a top view of the multiple connectors lined up to form a single story frame. In this embodiment, the frames are alongside two shipping containers 210, which may be utilized as a living space. Thus, two shipping containers 210 may be utilized as storage space, and in between the modular connectors may create a frame to develop a frame for a house. The framing may include a flooring base for multiple levels. In other embodiments, the connectors may be utilized as a roof of the house. In yet another embodiment, the connectors 110 may be aligned and laid over the shipping container to create a roof. The shipping containers 210 and connectors 110 may be welded to one another to secure one another to make a home.

FIG. 2B shows an embodiment of a two-story home utilizing the apparatus. While a two-story home is depicted, any type of home may be utilized. In such an embodiment, a floor connector may be utilized. A flat surface of the middle portion of the floor connector that is away from the bottom side of the floor connector may align with the connector portion upon assembly. The floor connector is discussed in more details in FIG. 2C below. The floor connector may be aligned with the main connectors to install a subfloor. Thus, additional connectors may be utilized with the shipping container 210 to create a larger home or additional floors.

FIG. 2C is an example of a floor connector 250. As shown, a base portion 252 may be sitting flat. A trust can sit on a top surface 251 of the base. The base portion may include a middle portion 253 that runs vertical from one end of the base. The middle portion may be at a 90 degree angle with the top surface of the base portion. The floor connector may thus include a bottom side (e.g., a bottom portion) connected to a middle pillar. The middle pillar may be adjoined via a right angle with the bottom side. The top side may also be adjoined to the middle pillar via a 45 degree angle. The middle pillar may have a flat surface on both sides of the middle pillar. Again, the various angles may utilize a 45 degree angle at the perimeter and sides in order to conj oin with the main portion or connector portions. As shown in FIG. 2C, the top portion 255 may include an aperture 257 to allow for a bolt 150 or any other connector to adjoin the floor connector.

FIG. 3A is a side view of multiple main portions connected via a hinge. As shown, one or more hinges may connect via the top perimeter and bottom perimeter. In the embodiment shown, the hinge may be reversible, as the left most main connector is upside down relative to the three other connectors. Thus, the hinge may allow for movement of the connector to allow various shapes between multiple main connectors. The hinges may be removable.

FIG. 3B is another side view of a multiple main connectors connected via a hinge. In such an embodiment, multiple hinges 301 may be connected to a single main portion of a connector, thus along two other pieces to swing via respective hinges 301. Such a scenario may be utilized for a floor or wall setting of the frame. Additionally, it may be useful to utilize the hinges 301 to fold the modular connectors within a shipping container or another space.

FIGS. 3C and 3D are examples of configurations of the hinges 101 in operation.

FIG. 4A is a perspective view of a portion of multiple connectors. As shown, the main portions and connectors may align to form a wall. The wall may be any dimension, but in such an embodiment the frame is shown to build a 16 foot wall utilizing two main portions. The dimensions of the connectors may be utilized as such to fit in the shipping container when broke down.

FIG. 4B is a perspective view of a portion of multiple connectors that are framed. As shown, wood studs 405 (or any other type of stud) may be placed within the dimensions of the modulated wall. The studs may be filled with insulation material 410 (e.g., any type of insulation material) and then later sided to provide an exterior surface of the house. Additionally, windows may be fit within the frame and the studs.

In one embodiment, a storage container may include a pre-assembled modular home utilizing the modular connectors. Thus, the modular home may be pre-assembled with the modular connectors at a factory and shipped inside of the storage container. Thus, when the container home is on the site of residence, the connectors may be welded and the appropriate spot. This may allow the framing of a modular home to be complete when the connectors are removed via a crane, hand, or other tool. Thus, the amount of labor done at the site of residence is reduced since framing is substantially complete, if not fully complete. The assembly may include an automated erection system, which may include a system of electric motors, gears, pulleys, cables, automated mechanical arms and electronic controls, located within the container structure of the modular assembly, and which interact with a plurality of frame panels and unit panels to deploy and retract the plurality of frame panels and unit panels for constructing the shipping container configuration and building unit configuration.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments can be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes can include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, to the extent any embodiments are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments are not outside the scope of the disclosure and can be desirable for particular applications. 

What is claimed is:
 1. A modular home connector, comprising, comprising: a main portion, wherein the main portion is formed via a first side, a second side, and a third side, wherein the first side and the second side are opposite of one another and substantially paralleled with one another, wherein one or more ends of the first side and second side include a 45 degree angle with respect to the third side and at a perimeter of the first side or second side, wherein the first and second side are met by the third side, wherein the top perimeter of a first main portion aligns with the bottom perimeter of a second main portion; and a connector portion, wherein the connector portion includes a corresponding 45 degree angle to adjoin against a top perimeter of each side of the main portion and configured to connect two or more main portions via the connector portion.
 2. The modular home connector of claim 1, wherein the modular home connector includes a floor connector that includes a bottom portion connected to a middle portion, wherein the middle portion is adjoined via a right angle with the bottom portion, and a top portion adjoined to the middle portion via a 45 degree angle, wherein a flat surface of the middle portion that is away from the bottom portion aligns with the connector portion.
 3. The modular home connector of claim 1, wherein the main portion and connector portion are made of a same material.
 4. The modular home connector of claim 3, wherein the same material is aluminum material.
 5. The modular home connector of claim 1, wherein the floor connector is connected to the middle portion via a screw.
 6. The modular home connector of claim 1, wherein floor connector is configured to allow for installation of a subfloor.
 7. The modular home of claim 1, wherein the main portion is 8 foot long.
 8. The modular home of claim 1, wherein the connectors are configured to fit in a shipping container when broken down.
 9. A modular home connector, comprising, comprising: a main portion, wherein the main portion includes a first side, a second side, and a third side, wherein the first side and the second side are opposite of one another and substantially paralleled with one another, wherein one or more ends of the first side and second side include a 45 degree angle with respect to the third side and at a perimeter of the first side or second side, wherein the first and second side are met by the third side, wherein the top perimeter of a first main portion aligns with the bottom perimeter of a second main portion, wherein the main portion is configured to connect with a corresponding connector portion.
 10. The modular home connector of claim 9, wherein the a connector portion, wherein the connector portion includes a corresponding 45 degree angle to adjoin against a top perimeter of each side of the main portion and configured to connect two or more main portions via the connector portion.
 11. The modular home connector of claim 10, wherein the connector portion includes one or more apertures configured to secure a fastener to both the connector portion and the main portion.
 12. The modular home connector of claim 9, wherein two or more main portions connect to one another via a hinge.
 13. The modular home connector of claim 9, wherein the main portion is included in a shipping container.
 14. The modular home connector of claim 9, wherein the two or more ends includes one or more apertures for securing a fastener.
 15. A modular home connector, comprising, comprising: a main portion, wherein the main portion is formed via a first side, a second side, and a third side, wherein the first side and the second side are opposite of one another and substantially parallel with one another, wherein one or more ends of the first side and second side include a first angle with respect to the third side and at a perimeter of the first side or second side, wherein the first and second side are met by the third side, wherein the top perimeter of a first main portion aligns with the bottom perimeter of a second main portion; a connector portion, wherein the connector portion includes a corresponding second angle to adjoin against a top perimeter of each side of the main portion and configured to connect two or more main portions via the connector portion; and wherein the modular home connector includes a floor connector that includes a bottom portion connected to a middle portion, wherein the middle portion is adjoined via a right angle with the bottom portion, and a top portion is adjoined to the middle portion via a third angle, wherein a flat surface of the middle portion that is away from the bottom portion and aligns with the connector portion.
 16. The modular home connector of claim 15, wherein the third angle is 45 degrees.
 17. The modular home connector of claim 15, wherein the first angle, the second angle, and third angle are all 45 degrees.
 18. The modular home connector of claim 15, wherein the first angle, the second angle, and third angle are all a same degree.
 19. The modular home connector of claim 15, wherein the first angle and the third angle are 45 degrees.
 20. The modular home connector of claim 15,wherein the floor connector includes a first hole that aligns with either a second hole of the main portion or a third hole of the connector portion. 